Protective cap



Aug 30, 1932- 3.A W. PUNTON PROTECTIVE CAP Filed Aug. 18. 1931 2,Sheets-Sheet l INVENTOR www s E S S E N n w Aug- 30, 1932- c. w. PuN'roNPROTECTIVE CAP Filed Aug. 18. 1931 2 Sheets-Sheet 2 INVENTOR WITNESSESPatented Aug. 30, 1932 ETED STATES PATENT @FFICE CHARLES W. PUNTON,'OFPITTSBURGH, PENNSYLVANIA, ASSIGNOR T0 'MINE SAFETY APPLIANCES COMPANY,OF PITTSBURGH, PENNSYLVANIA, A CORPORATION 0F rnNNsYLvANIA PROTECTIVECAP Application filed August 18, 1931.

This invention relates to protective caps for use by miners and othersengaged in occupations where the head is endangered.

The headgear commonly worn by miners and those engaged in similaroccupations generally consists of a cap embodying conventional crown andvisor portions formed from leather, fibre, canvas, and the like toprovide a relatively sti structure. These caps are intended to oder moreor less re sistance to impact, so as to protect the wearers head fromdamage by falling objects. However, the caps used up to the time of thisinvention have been subject to serious disadvantages inherent in theirconstruction. F or instance, the stiff edge or periphery of the crownportion of the cap has been more or less sharp and of substantially thesaine thickness as the balance of the crown, so that impact upon thecap, as by falling rock or coal, drives this sharp edge against theears, injuring, or in some instances even severing them. Moreover, thematerials used heretofore for this purpose become softened by moisture,or under heat, and are otherwise damaged in use, thus materiallydecreasing their efficiency.

It is among the objects of this invention to provide protective capswhich are strong and rigid, are resistant to the action of moisture,mine acids, and heat, adapted to resist severe impact without injury tothe wearer, of simple construction, are readily made, and embodyadvantages of prior caps while eliminating or minimizing injury to theears.

A special object is to provide caps of the type referred to which arecapable of preventing electric shock when the cap contacts with liveelectric conductors.

The invention may be described in connection with the accompanyingdrawings, in which Fig. l is a longitudinal section through oneembodiment of the cap, taken on line I-I, Fig. 2; Figs. 2 and 3 bottomplan and front elevational views, respectively, of the cap shown in Fig.l; Fig. 4 a fragmentary longitudinal section through the upper crownportion of a modified construction; Fig. 5 a cross section through aninsulated rivet; Fig. 6 a fragmentary cross Serial No. 557,758.

section on an enlarged scale through another embodiment, showing areinforced construction; Fig. 7 a fragmentary longitudinal sectionthrough 'a cap showing another form of lamp holder; Fig. 8 a viewsimilar to Fig. 7 showing a modified lamp holder molded integrally withthe cap; Figs. 9 and l0 front elevation and plan views, respectively, ofthe holder shown in F ig. 8; and Figs. 11 to 18 views similar to Figs. 8to 10 showing another form of integrally molded lamp holder.

In accordance with the invention caps embodying its stated objects aremade by molding them integrally from a plastic adapted to providearigid, strong, hard and nonconducting structure, and by providing theirlower edge with means for preventing injury to the ears. In accordancewith the invention ear protection is afforded by providing the edge ofthe crown with a narrow outwardly extending flange, or bead. The capsthus provided are rigid, strong and durable, and they eliminate thedanger of electric shock by contact of the head with exposed electricalconductors. In particular, they overcome the disadvantage of prior capsas regards ear injuries, for upon impact on the cap the bead does notcut, but tends to slide over, the ears. Other advantages presently to bepointed out, are also attained.

Although protection to the ears may be had by providing a narrow flangeon the edges of the crown overlying the ears, it is preferred to extendit continuously around the periphery of the cap and to make its sectiongreater than that of the crown portion. In this manner the cap isstrengthened and reinforced against damage due to shock, and mostsuitably this result is enhanced by molding a reinforcing element in thebead. The crown may be, and preferably is, also reinforced against shockby molding into it a formable reinforcing element, such as duck or wirescreen.

Various plastics may be used satisfactorily in the practice of theinvention. For eX- ample, the caps may be made from beaten pulp, such aspaper p rgwggdpulp) which can be molded in a press to providemhard andvio strong structures satisfying the requirements of such caps. Theaddition of sizing or bonding material, as is customary, materiallyassists in using such beaten pulp. Other moldable materials may be used,but it is preferred to use plastics of the type comprising organiccondensation products, such as those coinmonly referred to as syntheticresins. Materials of this class are initially-plastic and moldable, butafter being subjected to appropriate heat and pressure they become veryhard, infusible, non-conducting, and insoluble in most solvents, diluteacids and alkalis. The material preferably used is that resulting fromcondensation of phenol and formaldehyde, and for the best results theplastic comprises condensation products mixed with a more or less finelydivided binder, such as chopped duck or the like. Or, if desired, thebeaten pulp referred to may be impregnated with these materials. Allsuch materials are termed plastics7 herein, for brevity of reference.

Having reference now to the drawings, the cap shown in Figs. 1 to 3comprises a molded structure having a dome-shaped crown portion 1extended at one end to form a visor 2. The periphery of the cap isprovided with a continuous outwardly extending iange or bead 3 ofsubstantially greater section than that of the crown. Preferably theouter, or upper, surface of the flange is continuous with the crown, thelower portion being thickened to provide the bulbous thickening shown.This provides a reinforcing bead which is especially suited for thepurposes of the invention. In order further to reinforce this portion ofthe cap, there is preferably molded in the bead a reinforcing element3a. Hemp rope has been found to be suitable for this purpose.

For most purposes the crown portion of the cap is also reinforced by asuitable material molded in the crown, as by a single layer ofreinforcing screen 4, Fig. l, totally embedded in the ytop of the crown.Experience has shown that there may be a tendency for the screen to,become displaced toward the lower surface of the crown in the moldingoperation. This may be overcome by using a reinforcing elementcomprising a plurality ofv layers, such as a screen supported by paper.A single layer of paper arranged between the screen and the innersurface of the crown may be used, but as shown in Fig. 4l screen lla ispreferably sandwiched between layers 5 of paper, this element beingmolded in the top of crown la. With caps of ordinary size a circle ofscreen about 6 inches in diameter sulficiently reinforces the structure.While other materia-ls may be used for this purpose, screen is desirablebecause it is readily shaped in molding, the wires slipping to assumethe proper shape.

Although caps reinforced in this manner will be satisfactory for manypurposes, greater strength, or resistance to breakage, is obtained byfurther reinforcing the crown. To this end a formable material, such asduck is molded in the crown. Substantial improvement in strength isobtained by molding a ring of duck in the crown adjacent the bead, butthe most satisfactory results are had by the use of one or more layers6, Fig. 6, of duck or the like extending from the edge substantially toscreen 4.-

The caps are made by placing a layer of suitable plastic, such asphenol-formaldehyde condensation product mixed with chopped duck, in anappropriate mold. The reinforcing element or elements, as the case maybe, are then disposed appropriately in the mold and covered by thebalance of the plastic.' .Upon heating and pressing in the mannercustomary with such materials the cap is formed' and assumes theproperties characteristic of these materials.

A feature of this invention resides in the provision of a head bandwhich is removable and adjustable to the heads of different wearers. Theformshown comprises a sweat band 7 'of cloth,t or other suitablematerial,l

disposed within and spaced from crown v1 by spaced cushioning padsZatarranged at intervals` between the band and the crown.

The band is bent under the back of thev pads, i

as shown in Fig. l, and the structure is held removably in the crown bymeans of a nonmetallic draw member 8 laced through holes 9 spaced aroundthe crown and in the band and pads. The body of the sweat band is cut asshown in Figs. l and 2 to form a plurality of flaps l() gathered at thetop by a draw string 11 to form a lining, shown best in Fig. l.

The sweat band thus provided is readily removable for replacement, andthe size and shape of the head-receiving opening defined by it may bechanged readily. Thus, by using thinner or thicker pads the area of theopening may be changed, or by appropriately positioning thick and thinpads its shape may be altered according to need. A par- Y ticularadvantage of this structure is that 'ventilation is assured by thespaces 12 between the ends of the pads, which provide for freecirculation of air inside of the crown.

Where'the caps are used by miners and for similar purposes they areprovided with lamp holders associated with the crown above the visor.These holders may assume a variety of forms, and they may be eitherattached to the caps after they are formed, or molded integrally withthem. The holder shown in Figs. l to 3 comprises a strip 14: of stiffleather or the like having outwardly projecting ears at its upper endconnected to the crown by rivets l5, and folded upon itself andconnected at its lower end to the as the flat hook carbide type.

visor by means of rivets 16. A strip of metal 17 provided with anoutwardly offset portion 18 for reception of a lamp is riveted to theupper part of the holder, as shown in Figs. 1 and 3.

The plastic used in these caps is a non-conductor so that should the capcontact with an exposed trolley wire or the like the current will not becarried to the wearer. In order to eliminate the possibility ofconduction of electric current to the head by rivets extending throughthe crown, rivets are of an insulated type. These may be formed readilyby embedding the head of an ordinary rivet, Fig. 5, in plastic 15a, suchas phenol-formaldehyde condensation product. The rivet is inserted fromthe outside through appropriate holes in the crown and strip 14, and,the embedded head being held in a suitable tool, the free end is upsetwithin -the crown. Rivets 16 used in the visor need not be of thisnon-conducting type because at this point of the cap there issubstantially no possibility of contact of the inner end of the rivetwith the wearer.

vthat shown in Fig. 3. f

The holders may also be molded integrally with the cap, as shown inFigs. 8 to 10. The crown 1c of this embodiment is molded with aprojection 22 overlying the visor portion and having a recess 23, Fig.9, in its lower end for reception of a metallic plate 24, Fig. 10, forholding lamps of the fiat hook carbide or a common form of electricminers types, the

.bracket of the lamp being inserted between plate 24 and a recess 25formed rearwardly thereof. In order to render the holder adapted toreceive other standard types of lamp, its upper portion is provided, asshown in Figs. 9 and 10, with a deep recess 26 having spaced grooves 27for receiving the hooks or clamps of various types of carbide andelectric cap lamps.

Still another form of holder is shown in Figs. 11 to 13. This comprisesa molded plastic block 28 attached to thev crown 1d by "f means ofinsulated rivets 29. Like the holder shown in Figs. 8 to 10, this one isadapted to hold a variety of lamps. A metal strip 30 is riveted in arecess 31, and a narrower deeper recess 32 receives the brackets oflamps such Holes 33. extending downwardly into the holder are providedfor round hook lamps.

In addition to providing maximum protection to the ears when struck adownward blow, the caps are strong, durable, light and comfortable towear. The Visors are also strong and resistant to deformation orbreakage, and to damage by mine water and other liquids. Being integralwith the crown it is held in fixed position. Thus it affords protectionto the face and eyes and helps to hold lamps and goggles in fixedposition, and so to get the most satisfactory results from suchaccessory equipment. These are substantial advantages over the leatheror canvas Visors used heretofore, which become loosened, or broken down.

The cushioned adjustable head-band reduces pressure on the head andinsures ventilation. It also makes it possible to manufacture but a fewsizes, because thebands are readily adjustable to alter the size andshape of the opening. The caps withstand very severe impact withoutinjury, are not affected by heat, moisture or mine acids, effectivelyprotect the wearer from electrical shock, and are not flammable.

According to the provisions of the patent statutes, I have explained theprinciple and construction of my invention and have illustrated anddescribed what I now consider to represent its best embodiment. However,I desire to have it understood that, within the scope of the appendedclaims, the invention may be practiced otherwise than as specilicallyillustrated and described.

I claim:

1. A safety cap comprising integral rigid crown and visor portionsformed of hard,

non-conducting molded plastic and provided l around their outer edgewith an outwardly extending strengthening and ear-protective bead havinga reinforcing element molded therein, and the crown containing areinforcing element embedded in said plastic to strengthen the crownagainst breakage.

2. A safety cap comprising integrally molded rigid crown and visorportions formed of hard, non-conducting molded plastic, the edge of saidcrown portion adjacent the ears being provided with an integrally formedear-protective bead, and the upper portion of said crown beingreinforced by a wire screen embedded in said plastic.

3. A safety cap comprising integral rigid crown and visor portionsformed of hard, non-conducting molded plastic, said portions beingprovided around the edge with an outwardly extending strengthening andear-protective bead, and the upper portion of the crown having embeddedtherein a reinforcing element composed of layers of wire screen andpaper.

4. A safety cap formed of a hard, non-conducting molded plastic of theorganic condensation product type, the cap comprising integrally moldedrigid crown and visor portions, a strengthening and ear-protectivecontinuous bead of substantially heavier section than said portionsintegral with and extending outwardly from the periphery of the cap, awire screen reinforcement embedded in said plastic in the upper portionof said crown, and a reinforcing element integrally molded in said 5bead.

5. A safety cap formed of a hard, non-conducting molded plastic, the capcomprising a rigid molded crown portion extended forward at one end toform a visor and provided .lo peripherally with an integral narrowoutwardly projecting flange of substantially heavier section than saidcrown, a rope reinforcing element molded in said flange, a wire scre-enembedded in said plastic in the upper.

l5 part of said crown, and a lamp holder molded integrally in said crownabove said visor.

6. A safety cap comprising molded rigid crown and visor portionsprovided peripherally with an integral narrow outwardly projectingflange of substantially heavier section than said portions, the capbeing formed of a hard, non-conducting molded plastic of thecondensation product type, the upper portion of the crown beingreinforced by a strengthening element comprising y layers of wire screenand paper embedded in said plastic, said flange having a reinforcingelement molded therein, and a lamp holder associated with the crownabove said visor.

7. A safety cap formed of hard, non-conducting molded plastic, the capcomprising integrally molded rigid crown and visor portions providedaround their outer edge with an outwardly extending strengthening andear-protective bead, the crown being reinforced in its upper portion andadjacent said bead portion by woven fabric reinforcing elej mentsmoldably embedded in said crown portions, and a sweat band replaceablydisposed in said crown andv adjustable to vary the size of itshead-engaging opening.

In testimony whereof, I sign my name.

CHARLES W. PUNTON.

